US9611572B2ActiveUtilityA1

Dimensionally stable nonwoven fibrous webs, and methods of making and using the same

80
Assignee: MOORE ERIC MPriority: Oct 14, 2010Filed: Oct 14, 2011Granted: Apr 4, 2017
Est. expiryOct 14, 2030(~4.3 yrs left)· nominal 20-yr term from priority
Inventors:Eric M. MooreJohn D. StelterMichael R. BerriganFrancis E. PorbeniMatthew T. ScholzKorey W. KarlsSian F. FennesseyScott J. TumanCordell M. HardyYifan Zhang
D04H 1/435D04H 1/541Y10T442/696Y10T442/608D01F 1/10D01F 6/92D01F 6/62D04H 1/5416D04H 1/5414D04H 1/5412D04H 1/4382
80
PatentIndex Score
3
Cited by
175
References
36
Claims

Abstract

Dimensionally stable nonwoven fibrous webs include a plurality of fibers formed from one or more thermoplastic polyesters and an antishrink additive, preferably in an amount greater than 0% and no more than 10% by weight of the web. The webs have at least one dimension which decreases by no greater than 12% in the plane of the web when heated to a temperature above a glass transition temperature of the fibers. The webs may be used as wipes.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
       1. A nonwoven web comprising a plurality of fibers, wherein the fibers comprise:
 one or more thermoplastic aliphatic polyesters; and 
 a semicrystalline antishrinkage additive in an amount greater than 0% and no more than 6% by weight of the web, wherein the antishrinkage additive forms a dispersed phase of discrete particulates randomly distributed in the aliphatic polyester fibers having an average diameter of less than 250 nm; wherein the particulates are in the form of spheres or ellipsoids; 
 wherein the thermoplastic aliphatic polyester is present in an amount of greater than 90% by weight of the thermoplastic polymer present in the fibers; 
 wherein the fibers exhibit molecular orientation; 
 wherein the fibers do not extend substantially endlessly through the web; and 
 wherein the web has at least one dimension in the plane of the web which decreases by no greater than 12% when the web is heated to a temperature above a glass transition temperature of the fibers in an unrestrained condition. 
 
     
     
       2. The nonwoven web of  claim 1 , wherein at least a portion of the fibers in the nonwoven web are staple fibers. 
     
     
       3. The web of  claim 2 , further comprising one or more alkyl, alkenyl, aralkyl or alkaryl anionic surfactants incorporated into the polyester. 
     
     
       4. The web of  claim 3 , further comprising a surfactant carrier. 
     
     
       5. The web of  claim 3 , wherein the anionic surfactant is selected from the group consisting of one or more alkyl, alkenyl, alkaryl and arakyl sulfonates; alkyl, alkenyl, alkaryl and arakyl sulfates; alkyl, alkenyl, alkaryl and arakyl phosphonates; alkyl, alkenyl, alkaryl and arakyl phosphates; alkyl, alkenyl, alkaryl and arakyl carboxylates; alkyl alkoxylated carboxylates; alkyl alkoxylated sulfates; alkylalkoxylated sulfonates; alkyl alkoxylated phosphates; and combinations thereof. 
     
     
       6. The web of  claim 5 , wherein the anionic surfactant is selected from the group consisting of (C8-C22) alkyl sulfate salts, di(C8-C18) sulfosuccinate salts, C8-C22 alkyl sarconsinate salts, C8-C22 alkyl lactyalte salts, and combinations thereof. 
     
     
       7. The web of  claim 3 , wherein the anionic surfactant is present in an amount of at least 0.25% and no greater than 8% by weight of the composition. 
     
     
       8. The web of  claim 1 , wherein the semicrystalline antishrinkage additive is selected from the group consisting of polypropylene, polyethylene, polyamides, polyesters, blends and copolymers thereof. 
     
     
       9. The web of  claim 8 , wherein the semicrystalline antishrinkage additive is semicrystalline polypropylene. 
     
     
       10. The web of  claim 3 , wherein the nonwoven web remains hydrophilic after more than 10 days at 45° C. 
     
     
       11. The web of  claim 2 , wherein the web further comprises synthetic fibers, natural fibers, and combinations thereof. 
     
     
       12. The web of  claim 2 , wherein the thermoplastic polyester is at least one aliphatic polyester selected from the group consisting of one or more poly(lactic acid), poly(glycolic acid), poly(lactic-co-glycolic acid), polybutylene succinate, polyhydroxybutyrate, polyhydroxyvalerate, blends, and copolymers thereof. 
     
     
       13. The web of  claim 2 , wherein the semicrystalline antishrinkage additive is semicrystalline polypropylene and is present in an amount from about 1% to about 6% by weight of the web. 
     
     
       14. The web of  claim 2 , wherein the fibers exhibit a median fiber size of no greater than 200 denier. 
     
     
       15. The web of  claim 2 , wherein the fiber is a bicomponent fiber. 
     
     
       16. The web of  claim 2 , wherein the nonwoven web is selected from the group consisting of a carded web, airlaid web, wetlaid web, or combinations thereof. 
     
     
       17. The web of  claim 2 , wherein the nonwoven web is bonded to form a hydroentangled web, a thermal-bonded web, a resin-bonded web, a stitch-bonded web, a needle-tacked web, or combinations thereof. 
     
     
       18. The web of  claim 2 , further comprising an antimicrobial component. 
     
     
       19. An article comprising the web of  claim 2  and a film, membrane, nonwoven, or scrim extrusion bonded or thermally laminated directly to the web. 
     
     
       20. A nonwoven web comprising a plurality of fibers, wherein the fibers comprise:
 one or more thermoplastic aliphatic polyesters; and 
 an antishrinkage additive in an amount greater than 0% and no more than 6% by weight of the web, wherein the antishrinkage additive forms a dispersed phase of discrete particulates randomly distributed in the aliphatic polyester fibers having an average diameter of less than 250 nm; wherein the particulates are in the form of spheres or ellipsoids 
 wherein the thermoplastic aliphatic polyester is present in an amount of greater than 90% by weight of the thermoplastic polymer present in the fibers; 
 wherein the fibers exhibit molecular orientation; 
 wherein the fibers do not extend substantially endlessly through the web; and 
 wherein the web has at least one dimension in the plane of the web which decreases by no greater than 12% when the web is heated to a temperature above a glass transition temperature of the fibers in an unrestrained condition. 
 
     
     
       21. The nonwoven web of  claim 20 , wherein at least a portion of the fibers in the nonwoven web are staple fibers. 
     
     
       22. The web of  claim 20 , further comprising one or more alkyl, alkenyl, aralkyl or alkaryl anionic surfactants incorporated into the polyester. 
     
     
       23. The web of  claim 22 , further comprising a surfactant carrier. 
     
     
       24. The web of  claim 22 , wherein the anionic surfactant is selected from the group consisting of one or more alkyl, alkenyl, alkaryl and arakyl sulfonates; alkyl, alkenyl, alkaryl and arakyl sulfates; alkyl, alkenyl, alkaryl and arakyl phosphonates; alkyl, alkenyl, alkaryl and arakyl phosphates; alkyl, alkenyl, alkaryl and arakyl carboxylates; alkyl alkoxylated carboxylates; alkyl alkoxylated sulfates; alkylalkoxylated sulfonates; alkyl alkoxylated phosphates; and combinations thereof. 
     
     
       25. The web of  claim 24 , wherein the anionic surfactant is selected from the group consisting of (C8-C22) alkyl sulfate salts, di(C8-C18) sulfosuccinate salts, C8-C22 alkyl sarconsinate salts, C8-C22 alkyl lactyalte salts, and combinations thereof. 
     
     
       26. The web of  claim 22 , wherein the anionic surfactant is present in an amount of at least 0.25% and no greater than 8% by weight of the composition. 
     
     
       27. The web of  claim 20 , wherein the nonwoven web remains hydrophilic after more than 10 days at 45° C. 
     
     
       28. The web of  claim 20 , wherein the web further comprises synthetic fibers, natural fibers, and combinations thereof. 
     
     
       29. The web of  claim 20 , wherein the thermoplastic polyester is at least one aliphatic polyester selected from the group consisting of one or more poly(lactic acid), poly(glycolic acid), poly(lactic-co-glycolic acid), polybutylene succinate, polyhydroxybutyrate, polyhydroxyvalerate, blends, and copolymers thereof. 
     
     
       30. The web of  claim 20 , wherein the antishrinkage additive is present in an amount from about 1% to about 6% by weight of the web. 
     
     
       31. The web of  claim 20 , wherein the fibers exhibit a median fiber size of no greater than 200 denier. 
     
     
       32. The web of  claim 20 , wherein the fiber is a bicomponent fiber. 
     
     
       33. The web of  claim 20 , wherein the nonwoven web is selected from the group consisting of a carded web, airlaid web, wetlaid web, or combinations thereof. 
     
     
       34. The web of  claim 20 , wherein the nonwoven web is bonded to form a hydroentangled web, a thermal-bonded web, a resin-bonded web, a stitch-bonded web, a needle-tacked web, or combinations thereof. 
     
     
       35. The web of  claim 20 , further comprising an antimicrobial component. 
     
     
       36. An article comprising the web of  claim 20  and a film, membrane, nonwoven, or scrim extrusion bonded or thermally laminated directly to the web.

Cited by (0)

No later patents cite this yet.

References (0)

No backward citations on record.